Re-foldable one piece box and lid

ABSTRACT

A re-foldable, multifunctional, flat packing, quick fold erect, one piece box &amp; lid incorporating an integral internal panel (B) or panels, in which the fold erect feature allows the base of the box to be held erected in a set up position by the folded incorporated integral internal panels whether or not the attached lid is open or closed, without the use of additional glue, adhesives, tape, clip, or other fastener.

BACKGROUND OF THE INVENTION

This invention relates to a multi-functional, flat packing, quick folderect, re-foldable one piece box and lid incorporating an integralinternal panel or panels.

Retail staff are under pressure to serve as many customers as possible,in a short a time as possible, and to focus their attention on theclient which they are serving.

Furthermore, there is limited storage space in business premises, retailspaces and in the logistics chain on the products journey from factoryto consumer. It is rare to find products, the box and contents producedin the same location or even region, and rarer still for the end use tobe in the same location as the production of the box, thus all boxes,lids and fitments require some form of transportation or storage.

In addition, freight is charge by volumetric weight (volume and weightused in cost calculation), so shipping set-up boxes means paying forshipping the contents (be it air or products) also.

Brands and business are under continual pressure to offer high qualityproducts, in a well-designed presentation or packaging that is fit forpurpose.

BRIEF SUMMARY OF THE INVENTION

To overcome this, this invention proposes a re-foldable,multi-functional, flat packing, quick fold erect, one piece box and lidincorporating an integral internal panel or panels. This invention issuch that the lid, base and incorporated integral internal flapmechanism are joined together as one piece, the box can be assembled anddisassembled very quickly and easily without the need to use glue orother fasteners or adhesives as the base of the box is held in an erectset-up position by folded panels incorporated into the body of the boxand lid. This allows the box and lid to be re-used and re-folded, itfrees the hands of the end-user, the quick assembly without glue orother adhesives means minimal time or effort is required for set up ordisassembly by the end user.

The folded erect set-up feature of the box allows the base of the box tobe erected into a set-up position, whether or not the lid is closed oropen, whilst at the same time hiding the internal mechanism of the baseof the box. This offers a very presentable and practical solution, andthe box is designed to minimise the amount of raw edges showing on themain faces as the folding panels cover the internal mechanism.

The invention can also be flat packed, saving valuable space in retail,home, business and logistics environments. The flat packed feature alsorequires less packaging for transportation (fewer export cartons) and ismore secure for transportation - as set-up boxes are more likely to bedamaged.

The one piece format of the box, which includes the box, lid &incorporated integral flap and also the possibility of an integratedinternal fitment (which will be described in more detail later) meansthat the processes of setting up the box and lid is simplified for theend user and it also removes the need for a separate lid and base. Theinternal flap can also be modified to act as an integrated fitment tothe contents or product(s), again removing the need for a separatefitment.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

The invention will now be described solely by way of example and withreference to the accompanying drawings:

FIG. 1: shows the exploded perspective view of the box, neither flatpacked or set-up but in a state of flux between the two states.

FIG. 2: shows the exploded top view of the major and minor panels thatmake up the box.

FIG. 3: shows the exploded top view of the panels that make up the box.

FIG. 4: shows the perspective view of the box, neither flat packed orset-up but in the early stages of setting up the box from a flat packedposition.

FIG. 5: shows the perspective view of the box and how part C1 is foldedin the setting up the box from a flat packed position.

FIG. 6: shows the perspective view of the box and how part B, inparticular B1, is folded in the setting up the box from a flat packedposition.

FIG. 7: shows the perspective view of the box and how part B, inparticular B2, is folded in the setting up the box.

FIG. 8: shows the perspective view of the box and how part B theintegral attached flap, in particular B2, holds the base in an erectedposition.

FIG. 9: shows the box in a set up position with the lid closed.

FIG. 10: shows an alternative version of the box with a panel or windowin the lid.

FIG. 11: shows an alternative version of the box with a panel or windowin the lid.

FIG. 12: shows an alternative version of the box in differentproportions & size.

FIG. 13: shows an alternative version of the box in differentproportions & size.

FIG. 14: shows an alternative version of the box in differentproportions & size.

FIG. 15: shows an alternative version of the box in differentproportions & size.

FIG. 16: shows an alternative version of the box in differentproportions & size.

FIG. 17: shows an alternative version of the box in differentproportions & size with a carrying handle.

FIG. 18: shows an alternative version of the box in differentproportions & size with a carrying handle.

FIG. 19: shows an alternative version of the box in differentproportions & size with a carrying handle.

FIG. 20: shows an alternative version of the box in differentproportions & size with a carrying handle.

FIG. 21: shows an alternative version of the one-piece box with anintegral fitment attached to panel B.

FIG. 22: shows an alternative version of the one-piece box with anintegral fitment attached to panel B.

FIG. 23: shows an alternative version of the one-piece box with anintegral fitment attached to panel B.

FIG. 24: shows an alternative version of the one-piece box with anintegral fitment attached to panel B.

FIG. 25: shows an alternative version of the one-piece box with anintegral fitment attached to panel B.

FIG. 26: shows an alternative version of the one-piece box with anintegral compartment attached to panel B.

FIG. 27: shows an alternative version of the one-piece box with anintegral compartment attached to panel B.

FIG. 28: shows an alternative version of the one-piece box with anintegral compartment attached to panel B.

FIG. 29: shows an alternative version of the one-piece box with anintegral compartment attached to panel B.

FIG. 30: shows an alternative version of the one-piece box closed with astud holding the lid shut.

FIG. 31: shows an alternative version of the one-piece box closed with alock holding the lid shut.

FIG. 32: shows an alternative version of the one-piece box closed with atag closure.

FIG. 33: shows an alternative version of the one-piece box closed with atag holding the lid.

FIG. 34: shows an alternative version of the one-piece box closed withribbon closure.

FIG. 35: shows an alternative version of the one-piece box closed withribbon holding the lid shut.

FIG. 36: shows an alternative version of the one-piece box closed withVelcro holding the lid shut.

FIG. 37: shows an alternative version of the one-piece box closed withelastic holding the lid shut.

FIG. 38: shows an alternative version of the one-piece box closed with amagnet holding the lid shut.

FIG. 39: shows an example of the box in a flat packed position, in thefirst stage of further folding the panels whilst flat packed to minimisethe area the box takes up, in this case C1 is folded inwards.

FIG. 40: shows an example of the box in a flat pack position, with panelC1 folded inwards.

FIG. 41: shows an example of the box in a flat pack position, with anarrow illustration how panels B1 and B2 are folded inwards.

FIG. 42: shows an example of the box in a flat pack position, withpanels A4 and A5 being folded to reduce the amount of area the flat packbox takes up.

FIG. 43: shows an example of the box in a flat pack position, with thepanels folded.

DETAILED DESCRIPTION OF THE INVENTION

The basic structure of the box is made up of a number of panels,including the main body (A1, A2, A3, A4, and A5), end flap (C1),incorporated integral internal panel (B1, B2) and side walls (D1, D2,D3, D4, D5 and E1, E2, E3, E4, E5) as shown on FIG. 1, FIG. 2, FIG. 3.These panels are made flexible and foldable through the use of materialsbetween the panels that have been pre-cut, pre-creased, pre-folded, orby connecting the panels with a flexible material, which may be athicker or thinner substrate, or may connect the panels totally to eachother or in part, as referred to in claim 4.

Panel A, which comprises the main body of the box, including the basepart and the lid, is made up of 5 smaller panels (A1, A2, A3, A4 andA5). In a folded position, A1, A2, A3 together make up the base of thebox, with parts A4 and A5 making up the lid as shown in FIG. 6, FIG. 7and FIG. 8.

Panel B, which is the incorporated internal flap and/or integratedfitment, is connected to the join between panels A3 and A4 with aflexible material. Panel B is made up of parts B1 and B2.

Panel C1 is connected to the end of Panel A to part A1 using a flexiblematerial. Panel C in this example is constructed of 1 panel piece only,however, this can be altered in size or structure and additional panelsor parts may be added as per claim 5.

Panel D and Panel E are the side flaps for the box, each made up of 5panels joined to each other by a flexible material, as illustrated inFIG. 1, FIG. 2 and FIG. 3.

The edge of D1, D3 and D5 and correspondingly the edge of E1, E3, and E5are joined respectively to each side of the panels A1, A2 and A3, andlie flat against the surface of A1, A2 and A3 when the box is in a flatposition, FIG. 4 shows the location of panels D and E. D1 andcorrespondingly E1 are affixed to panel A1, this attachment eases theassembly of the box for the end user, although this construction stillworks if D1 and E1 are not permanently affixed. D5 and respectively E5are affixed to panel A3, as illustrated in FIG. 4.

The join between D3 and A2, and correspondingly the join between E3 andA2, are flexible so that D3 and E3 can lie flat against the surface ofA2 or fold upwards to a position at 90 degrees to the surface of A2, asillustrated in FIG. 4, FIG. 5, FIG. 6 and FIG. 7.

The positions of the panels, the flexible joins between the individualpanels making up the main parts of the box, are such that the box can beassembled into a setup position and easily disassembled into a flat packposition. The process of folding into a set-up position is illustratedstep by step in FIG. 4 through to FIG. 9 inclusively. This process caneasily be reversed to unfold the boxes back to a flat pack position.Ribbons, or an alternative method, can be added to the edge of panel B2and also C to make unfolding even simpler as they provide an area thatcan easily be gripped by the user to unfold the panels; this ribbon isillustrated in FIG. 4 through to FIG. 7 attached to B2. Alternativesolutions for gripping the edge of the panels could also be used, anexample of which is small cuts or finger holes.

To assemble from a flat position, A1 and A3 are pushed towards eachother by the end user (either by holding onto the Lid (A4 and A5) andend flap C, or some other location) such that A1 and A3 lie at 90degrees against the surface of the inner face of panel A2, asillustrated by FIG. 4, FIG. 5 and FIG. 6. This motion will automaticallyfold D3 and E3 into a vertical (90 degree) position against the innersurface of A2, if the parts D1, D5, E1 and E5 have been affixed to A1and A3 respectively as described above, otherwise the user will need topush these parts in. The position of the flaps is now such that A1, A3,D3 and E3 all lie at 90 degrees to the inner surface of A2, thus formingthe beginnings of the base structure of the box. Due to the folding upof Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4 andE5 will all fold together such that their surface lie flat against eachother, this processes is illustrated in FIG. 6, where D4 and D5, E4 andE5 are pushed towards each other as the box is set up.

Panel C1 is then folded over such that its inner surface lies flatagainst the inner surface of panel A1, as illustrated in FIG. 5. Thepanel C1, in its folded position, will cover the panels D1 and D2, E1and E2, so that they lie underneath panel C1, between C1 and A1.

An integral feature of this flat packing, quick fold erect, re-foldableone piece box & lid, the incorporated Panel B, is then folded over suchthat the inner surface of part B1 lies flat against A3, as shown in FIG.6 and FIG. 7. The panel B1, in its folded position, will cover thepanels D4 and D5, E4 and E5, so that they lie underneath panel B1between B1 and A3.

The Panel B2, is then be pushed down so that it lies flat against thepanel A2 as illustrated in FIG. 7 and FIG. 8. The pushing down of panelB2, or an incorporated panel added for this purpose, has the effect ofholding panel C1 and B1 in place in their folded positions, henceholding the base of the box in a set up position, as illustrated in FIG.7, FIG. 8. Thus the bottom part of the box is now erected with A1, A3,D3 and E3 all at 90 degrees to the inner surface of A2 and held in placeby the folding of the inner panels B and also C1 as described above, asillustrated by FIG. 8. With the flaps in this position, the bottom partof the box will remain erected whether or not the lid, comprised of A4and A5 is opened or closed.

The panel A4 can be folded over the top of the erected bottom part ofthe box to act as a lid or cover, with the panel A5 folding over theouter surface of A1, as illustrated by FIG. 9. To keep the lid closed onthe box when in an erected position, A5 can be attached to the outersurface of panel A1 through the use of magnets, clips, cuts, additionalparts, ribbons, ties or other method as per claim 8.

FIG. 10 and FIG. 11 illustrate an alternative version of this invention,with a panel or window in the lid panel A4. A panel, window or cut outcan be included on any panel or side of the box or lid, to act as anadornment, decoration, feature or to allow visibility or access to theproducts.

FIG. 12, FIG. 13, FIG. 14, FIG. 15 and FIG. 16 illustrate an alternativeversion of this invention in various sizes and proportions.

FIG. 17, FIG. 18, FIG. 19 and FIG. 20 illustrate an alternative versionof this invention with a handle (H1) attached to a panel in varioussizes and proportions. The invention could be made with other methodsfor carrying it attached to any location on the outer or inner surface,or carrying method not attached directly to the product. Attachmentscould also be added for as a feature or for decorative or adornmentpurposes to the outside or inside of this invention. A handle, made froma ribbon, string or other material could be affixed to the outer surfaceof panel A1 such that it passes through a cut, whole or slot in A5, oron any other panels, to act as a handle or adornment, or decoration orother use, as per claim 7.

FIG. 21 illustrates an alternative version of this invention with anincorporated integrated fitment. The fitment in this example is theresult of foldable panels (of which B5, B7 and B8 are visible in FIG.21) incorporated and attached on to either side of panel B2, such thatthe panels fold and act as a fitment. Panels B3, B4, B5, B7 and B8,which in this example are additional panels connected to the main B (B1and B2) panel, are visible (although not all these panels feature ineach drawing) in FIGS. 21 through to FIG. 25 inclusive, they fold so asto form a fitment, that in this example is an extension of panel B2.These panels are made flexible and foldable through the use of materialsbetween the panels that have been pre-cut, pre-creased, pre-folded, orby connecting the panels with a flexible material, which may be athicker or thinner substrate, or may connect the panels totally to eachother or in part, as referred to in claim 4. The panels may have a cutout or slits to hold the product when the fitment is folded in place inthe set up position, as illustrated in FIG. 22, FIG. 23, FIG. 24 andFIG. 25.

There are a number of ways in which a fitment can be integrated intothis invention, including altering the size, shape and number of panels,adding flaps, parts, cuts or interlocks to create an integrated fitmentas per claim 10, claim 11 and claim 12. Some additional examples ofalternatives for integrated fitment are illustrated in FIG. 22, FIG. 23,FIG. 24 and FIG. 25, which show fitments made using more incorporatedintegral panels, flaps, interlocks, cut outs, slots, holes and slits. Inthese examples, the fitment can also be flat packed, and is directlyconnected to the box.

More panels or parts can be incorporated to the existing panels andflaps. The existing panels which make up the box may also be changed insize, proportions and or structure, for example to act as a fitment orinternal compartment.

This invention can also be made by altering the panel B2 orincorporating more panels, flaps, parts, cuts or interlocks so that theinvention is held together in an erect set up position without the needfor the panel B2 to touch or lie flat against the inner surface of thepanel A2, as illustrated by the example FIG. 23 in which more panelshave been incorporated onto the box to act as a fitment and also to holdthe base of the box erect.

The box and lid could also be lined on the inside or the outside withmaterial for decorative purposes or to protect the contents when in aset-up position. The box and lid could be lined with fabric material.

FIG. 26, FIG. 27, FIG. 28 and FIG. 29 illustrate an alternative versionof this invention with an incorporated integral integrated compartment.The panels making up the compartment may be integrated with panel B2, asan extension of panel B2 or it may be incorporated to the other panelsthat make up the box and lid, or new panels or flaps incorporated to thebox. FIG. 26 illustrates the use of additional incorporated panels(panel B3 is visible in FIG. 26) to act as an integrated compartmentwhen folded in the set-up position. More panels can be integrated toform a combination of compartments and fitments. This is illustrated bythe panels B3, B5, B6, B7, B8, B9 which are visible in figures 26through to 29 inclusively (although not all panels feature in eachdrawing), and act as an integral integrated compartment, as they areattached to the main panel B (B1 and B2)

FIG. 30, FIG. 31, FIG. 32, FIG. 33, FIG. 34, FIG. 35, FIG. 36, FIG. 37and FIG. 38 illustrate an alternative version of this invention withalternative methods for holding the lid (in this example parts A4 andA5) closed. The examples include the use of magnets (FIG. 38), ribbons(FIG. 34 and FIG. 35), studs clips, locks, Velcro and straps.

A key feature of the box is that the box, lid and incorporated integralinternal panels can be folded into a flat packed position. FIG. 39illustrates a top view of the box in a flat packed position. FIGS. 39through to FIG. 43 inclusive show how the panels of the box can befurther folded, to minimise the area the flat packed box takes up. FIG.39 shows how panel C1 is folded over. FIG. 41 illustrates how panels B1and B2 are folded over the inside face of panels A1, A2, A3 and thefolded panel C1. FIG. 42 shows how panels A4 and A5 are folded aroundthe back of the box. FIG. 43 shows another example of how the box can beflat packed, with panels A4 and A5 folded around the back, and panelsB1, B2 and C1 folded over the inside of the box, all in a flat packedposition. The folding of the panels reduces the amount of area the boxtakes up, making it easier to store and also more compact for shippingwhich reduces the risk of damage in transit, as well as saving space.

1. A re-foldable, multifunctional, flat packing, quick fold erect, onepiece box & lid incorporating an integral internal panel or panels, inwhich the fold erect feature allows the base of the box to be helderected in a set up position by the folded incorporated integralinternal panels whether or not the attached lid is open or closed,without the use of additional glue, adhesives, tape, clip, or otherfastener.
 2. A re-foldable, multifunctional, flat packing, quick folderect, one piece box & lid incorporating an integral internal panel orpanels according to claim 1, with a folding lid, folding side walls andincorporated integral internal folding panels, in which the lid,integral internal panels and side walls are attached to the main body ofthe box, and all are foldable such that the structure folds to form afully covered complete box with attached lid (and not a box comprised ofa separate lid and base parts).
 3. A re-foldable, multifunctional, flatpacking, quick fold erect, one piece box & lid incorporating an integralinternal panel or panels according to claim 1, in which the box can beassembled from the flat pack position to the set-up position and the boxcan be disassembled and returned to the flat pack position, without theuse of adhesives, double sided tape, tape, or other fastener to hold itin the set-up position.
 4. A re-foldable, multifunctional, flat packing,quick fold erect, one piece box & lid incorporating an integral internalpanel or panels according to claim 1, in which the lid, side walls, baseand internal flaps are made flexible and foldable through the use ofmaterials that have been pre-cut, pre-creased, pre-folded, or through byconnecting the panels making up the sides and parts of the box with aflexible material, which may be a thicker or thinner substrate, or mayconnect the panels totally to each other or in part.
 5. Amultifunctional, flat packing, quick fold erect, re-foldable one piecebox & lid according to claim 1, in which the box, lid and integralpanels can be of varying dimensions, proportions, and sizes.
 6. Are-foldable, multifunctional, flat packing, quick fold erect, one piecebox & lid incorporating an integral internal panel or panels accordingto claim 1, in which any part of the box, lid or integral panels mayhave a window, slot, cut out or panel or may have part of the materialreplaced by a different material which is clear, see-through or notsee-through to act as a window, or adornment or decoration, or access tothe product.
 7. A re-foldable, multifunctional, flat packing, quick folderect, one piece box & lid incorporating an integral internal panel orpanels according to claim 1, on which a carry mechanism, handle or partby which the box can be carried is added to any of the internal orexternal panels, including but not limited to a ribbon, string, plastic,paper or metal handle affixed to the box.
 8. A re-foldable,multifunctional, flat packing, quick fold erect, one piece box & lidincorporating an integral internal panel or panels according to claim 1,in which the lid in a closed arrangement can be held in position bymagnets, a ribbon, a clip, a slotting method, or other such method forsecuring the position of the lid of the box when in a set-uparrangement, or the lid can be left open and unattached.
 9. Are-foldable, multifunctional, flat packing, quick fold erect, one piecebox & lid incorporating an integral internal panel or panels accordingto claim 1, in which the internal panel holds the box in an erect set upposition by a fold erect mechanism of internal panels or by engagingfrictionally, via slots or cuts in either flap, via a clip, or magnet,or by altering the shape of the panels or by interlocking between panelsof the box, including more incorporated panels.
 10. A re-foldable,multifunctional, flat packing, quick fold erect, one piece box & lidincorporating an integral internal panel or panels according to claim 1,in which the internal flaps or panels act as a fitment.
 11. Are-foldable, multifunctional, flat packing, quick fold erect, one piecebox & lid incorporating an integral internal panel or panels accordingto claim 1, in which the internal flaps have additional panels, flaps ormaterial attached to them to support a product as a fitment, or to actas an adornment or decoration.
 12. A re-foldable, multifunctional, flatpacking, quick fold erect, one piece box & lid incorporating an integralinternal panel or panels according to claim 1, in which the internalflaps have panels attached to them, or material cut out from them or thesize or shape alerted in order to support a product as a fitment, or toact as an adornment or decoration.
 13. A re-foldable, multifunctional,flat packing, quick fold erect, one piece box & lid incorporating anintegral internal panel or panels according to claim 1, in which theinternal flaps have additional panels, flaps or material attached toform a compartment or multiple compartments.
 14. A re-foldable,multifunctional, flat packing, quick fold erect, one piece box & lidincorporating an integral internal panel or panels according to claim 1,where part or all the materials are lined or coated with fabric or othermaterials, or various materials are used to make up the parts of thebox.
 15. A re-foldable, multifunctional, flat packing, quick fold erect,one piece box & lid incorporating an integral internal panel or panelsaccording to claim 1, which can be fixed permanently in a set upposition the use of additional glue, adhesives, tape, clip, or otherfastener, or interlocking, clips or other method for permanently holdingthe box in a set-up position.